Breakthrough in Composite Material Development: Russian Scientists Create Lightweight, Ductile Aluminium-Based Composite

A team of Russian scientists, led by Professor Dmitry Shtansky from NITU MISIS (Moscow), has developed a groundbreaking aluminium-based composite material. This new composite not only rivals the strength of steel but is also three times lighter and exhibits superior plasticity compared to similar materials. This innovation holds significant potential for applications in the automotive and aviation industries.

Key Features of the Composite

• Lightweight and Strong: The composite is three times lighter than steel while maintaining comparable strength.
• Thermal Resistance: It retains high mechanical properties even at temperatures up to 500 degrees Celsius, outperforming many existing metal matrix composites.
• Unique Composition: The material comprises micron and submicron-sized aluminium grains, surrounded by a “framework” of a mixture of aluminium oxide and metallic aluminium.

The composite is produced by mixing aluminium and aluminium oxide nanopowders, which are then ground using a ball mill. The resultant mixture is processed using a spark plasma sintering system. This process yields a composite that is not only lightweight and strong but also exhibits a wide range of strength across different temperatures.

Innovative Thermomechanical Properties

Among several variants of aluminium composites developed, one containing 3% aluminium oxide showed the most promising thermomechanical properties. The material demonstrated strength comparable to steel at high temperatures and an almost “metallic” ductility, attributed to its unique “double” structure.

The new composite's high ductility makes it more resistant to micro-cracks and deformations than current aluminium composites. This resilience is crucial for parts constantly subjected to mechanical and thermal stresses in cars and